Shoe outer sole with surface portions for flocking

ABSTRACT

The shoe outer sole includes a ball region and a heel region. The ball region includes a first and second longitudinally extending lobes, with a narrower third middle lobe connected therebetween, for adhering flocking to the shoe outsole. The heel region includes fourth and fifth lobes connected together and forming a J-shape conforming to an outside area of a heel of a wearer, for adhering flocking to the shoe outsole.

BACKGROUND

This invention relates to an outer sole or outsole for a shoe, and in particular relates to an outer sole or outsole with a tread for a casual shoe or slipper, with predetermined, delineated bottom ball and heel surface portions on the outer sole or outsole that are configured for application of and adhering flocking to the bottom ball and heel surface portions, as well as an outer sole or outsole for a shoe with flocking applied and adhered to the bottom ball and heel surface portions.

Conventional flocking of portions of shoes typically has involved deposition of fibrous particles, also referred to as flock, onto a surface of a shoe, such as portions of uppers for coloring, decoration, texture, appearance, embossing, reducing reflectivity, or insulation, for example; on the bottom of stiletto heels of women's shoes for alteration of frictional characteristics, reduction of slipping and wear, and padding for cushioning and comfort; and in the lining of an insole for such purposes. Flocking is typically applied to an adhesive coated surface, such as by application of a high voltage electrical field to the surface to initially attract particles of flocking to the adhesive coated surface, and cured, or by vulcanizing the substrate material of the surface with flocking initially adhered to the surface in order to bond the flocking to the substrate material. Flocking has also been applied to conventional socks and hiking shoes to improve traction on wet or otherwise slippery surfaces. Flocking can also be sprayed onto polyurethane substrate material and cured in place.

One known method for applying flocking to an outsole of shoe under pressure involves application of flocking fibers to an outsole of a shoe by placing the fibers in a chamber within a housing and placing the outsole over an opening in the housing after applying an adhesive to a surface of the outsole which is to receive the flocking. A pressurized gas jet is activated to increase the pressure in the housing thereby causing the fibers to exit the chamber and collide with the adhesive surface of the outsole. The outsoles may be supported on screens within openings in a tray which is removably mountable on the housing over the opening therein.

Other conventional methods for electrostatic flocking of fabric shoe outsole are known, in which adhesive is applied to at least a portion of a bottom surface of a shoe outsole, and a plurality of fibers are embedded within the adhesive. Once an adhesive is applied to the outsole, fibers can be sifted down through an electrostatic field onto the adhesive, and once sufficient fibers have been embedded, the adhesive can then be cured and cooled.

Another known process for applying a flocked coating to a cloth surface such as a tennis shoe, involves applying a flocking fiber to a cloth surface of a shoe, by spraying a clean dry cloth shoe with an adhesive. Flock fibers suitable for application are carried by a charge in an electrostatic field, in a flocking chamber, and the flock fibers are applied so that they adhere to the adhesive surface. Another similar process is known in which flocking fibers are applied to an outsole of a shoe by placing the fibers in a chamber within a housing and placing the outsole over an opening in the housing after applying an adhesive to a surface of the outsole which is to receive the flocking. A pressurized gas jet is activated to increase the pressure in the housing to cause the fibers to contact the adhesive surface. Another known process for applying flocking to a shoe involves applying knitwear to an outer sole or a midsole.

It would be desirable to provide predetermined, delineated bottom ball and heel surface portions on the outer sole or outsole that are configured for application and adhering flocking to the bottom ball and heel surface portions, as well as an outer sole or outsole for a shoe with flocking applied and adhered to the bottom ball and heel surface portions, in order to further improve cushioning of the shoe outsole in particular regions of pressure or stress on a user's foot, to better accommodate such pressure or stress on a user's foot, and to further improve traction of the shoe outsole in the particular regions of pressure or stress on a user's foot.

It would be desirable to provide tread patterns of raised and recessed portions or ridges and grooves of the shoe outer sole or outsole inside the predetermined stress regions of the ball area and heel of the shoe outsole in order to improve adhesion of flocking to the shoe outer sole or outsole in the predetermined stress regions of the ball area and heel of the shoe outsole.

It would be desirable to provide tread patterns of raised and recessed portions or ridges and grooves of the shoe outer sole or outsole outside of the predetermined stress regions of the ball area and heel of the shoe outsole in order to improve cushioning and traction of the shoe outer sole or outsole. The present invention satisfies these and other needs.

SUMMARY OF THE INVENTION

Briefly, and in general terms, the invention provides for a shoe outsole to which flocking is to be adhered or otherwise affixed in particular regions of pressure or stress to which a user's foot is typically subjected, in the heel and ball area of the shoe outsole, in order to improve cushioning and traction, at least in the particular regions of the shoe outsole.

The present invention accordingly provides for a shoe outsole having a front toe, a rear heel, and medial and lateral side edges therebetween, a length with a longitudinal axis, a width, and a main bottom surface. The shoe outsole includes a ball region of the shoe outsole in an area of a ball of a wearer's foot, and a heel region of the shoe outsole in an area of a heel of a wearer's foot. The ball region preferably has a contiguous shape with a first longitudinally extending lobe, a second longitudinally extending lobe, and a narrower third middle lobe connected therebetween, forming a “butterfly” shape. The ball region of the shoe outsole also preferably includes a tread pattern having first ridges and grooves extending laterally perpendicular to the longitudinal axis. In another presently preferred aspect, the ball region of the shoe outsole has a bottom surface additionally including second ridges and grooves extending longitudinally between the first ridges and grooves to provide surfaces for adhering flocking to the ball region of the shoe outsole.

The heel region of the shoe outsole also preferably has a contiguous shape with fourth and fifth lobes connected together and forming a J-shape conforming to an outside area of a heel of a user. In a presently preferred aspect, the fourth lobe extends generally longitudinally along the outside area of the heel of the wearer, and the fifth lobe extends generally perpendicular to the fourth lobe generally along a rear area of the wearer's heel. In another presently preferred aspect, the heel region has a bottom surface having the tread pattern including first ridges and grooves extending laterally perpendicular to the longitudinal axis, and additionally preferably includes third ridges and grooves extending longitudinally to provide surfaces for adhering flocking to said heel region.

In another presently preferred aspect, at least a portion of the main bottom surface of the shoe outsole includes the tread pattern including the first ridges and grooves. In another presently preferred aspect, at least a portion of the first ridges and grooves of the main bottom surface additionally include second ridges extending longitudinally. In another presently preferred aspect, the first longitudinally extending lobe is disposed on a medial portion of said ball region of the shoe outsole. In another presently preferred aspect, the first longitudinally extending lobe is longer than the second longitudinally extending lobe.

In another presently preferred aspect, the second longitudinally extending lobe is disposed on a lateral portion of the ball region of the shoe outsole. In another presently preferred aspect, the second ridges extend outwardly beyond said first ridges and grooves. In another presently preferred aspect, the shoe outsole further includes flocking adhered to the bottom surface of the ball region, and the shoe outsole further includes flocking adhered to the bottom surface of the heel region.

Other features and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments in conjunction with the accompanying drawings, which illustrate, by way of example, the operation of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a shoe outsole for a shoe, according to the present invention;

FIG. 2 is a bottom plan view of the shoe outsole of FIG. 1, of which a matching shoe of a pair is a mirror image;

FIG. 3A is cross-sectional view of the shoe outsole of FIG. 2 taken along line 3A-3A;

FIG. 3B is a cross-sectional view of the shoe outsole of FIG. 2 taken along line 3B-3B;

FIG. 3C is a side, elevational view of the shoe outsole of FIG. 1; and

FIG. 4 is a bottom plan view of the shoe outsole of FIG. 2 showing flocking which has been placed on the bottom ball region and heel region of the shoe outsole.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the drawings, which are provided for purposes of illustration and by way of example, the present invention provides for a shoe outsole to which flocking is to be adhered or otherwise affixed in particular regions of pressure or stress to which many common types of feet of users have been found to be most subjected, in the heel and ball areas of the shoe outsole, in order to improve cushioning and traction, at least in those particular regions of the shoe outsole.

Referring to FIGS. 1 to 4, the shoe outsole 10 is typically formed as one piece, with no split or seam in the front or back, and is typically provided for attachment to midsole and upper portions of a shoe 12. The shoe outsole has a front toe 14, a rear heel 16, and medial and lateral side edges 18, 20 therebetween. As can be seen in FIG. 2, the shoe outsole 10 has a length 22 with a longitudinal axis 24, a width 26, and a main common region 28 having a tread pattern.

The tread pattern in the main common region 28 preferably includes first raised portions or ridges 30, and first recessed portions or grooves 32. The first raised ridges 30 and the first recessed grooves 32 preferably extend laterally perpendicular to the longitudinal axis. These first raised portions or ridges 30 in the main common region 28 generally have the same height although the height of raised ridges at the very front of the toe 14 and at the back edge of the heel 16 could be somewhat smaller to create a rocker sole or bottom.

Referring specifically to FIGS. 2 and 3B, the tread pattern may include second raised portions or ridges 34, which are typically thinner than the first raised portions or ridges 30, located on the surface of the first raised ridges 30 and which extend longitudinally with the longitudinal axis 24. Spaces 36 are formed between adjacent second raised 34 and extend likewise longitudinally with the longitudinal axis 24. In FIG. 2, these second raised ridges 34 are shown placed on only one of the first ridges 30 located in the main common region 28 for illustrative purposes. However, it should be appreciated that second raised ridges 34 could be placed on additional or all of the first raised ridges 30 located in the main common region 28. Additionally, it should be appreciated that these second raised ridges 34 could be selectively placed on the first raised ridges 30 to create a pattern which could help prevent slipping and wear.

The shoe outsole bottom surface preferably includes a first region or ball region 38 of the shoe outsole in an area corresponding to and supportive of a ball of a user's or wearer's foot. The first region or ball region 38 is preferably delineated by a first channel 40. The first region or ball region 38 preferably has a contiguous shape, generally having a “butterfly” shape, with a first longitudinally extending lobe 42, a second longitudinally extending lobe 44, and a narrower third middle lobe 46 connected between the first and second longitudinally extending lobes. The first longitudinally extending lobe 42 preferably is located on a medial side of the first region or ball region 38 of the shoe outsole, the second longitudinally extending lobe 44 preferably is located on a lateral side of the first region or ball region 38 of the shoe outsole, and the first longitudinally extending lobe 42 preferably is longer than the second longitudinally extending lobe 44.

The first region or ball region 38 of the shoe outsole 10 also preferably includes first raised portions or ridges 48 and first recessed portions or grooves 50 extending laterally perpendicular to the longitudinal axis 24. The height of the first raised portions or ridges 48 in the ball region 38 can be greater than the height of the first raised portions or ridges 30 located in the main common bottom surface 28 to provide additional cushioning to the wearer's foot in the ball area. (See FIG. 3A) Additionally, the longer height of the first raised ridges 48 in the ball region 38 creates a longer projection which can be used to secure the flocking (described below) to the shoe outsole 10. Generally, the height of the first raised ridges 48 in the ball region 38 is about 0.5 to 2.0 millimeters greater that the height of the first raised ridges 20 located in the main common region 28.

The first raised portions or ridges 48 in the ball region 38 can likewise include second raised portions or ridges 52 extending longitudinally to provide surfaces for adhering flocking to the ball region 38 of the shoe outsole. Spaces 54 are formed between adjacent second raised ridges 52. These second raised portions or ridges 52 also preferably extend outwardly beyond the first raised portions or ridges. Additionally, second raised ridges 52 could be placed on the surface of the recessed portions or grooves 50 formed in the ball region (not shown in the drawings) in order to improve adhesion of flocking to the shoe outer sole. In FIG. 2, these second raised ridges 52 are shown placed on only one of the first ridges 48 located in the ball region 38 for illustrative purposes. However, it again should be appreciated that second raised ridges 52 could be placed on additional or all of the first raised ridges 48 located in the ball region 38.

In a presently preferred embodiment, the shoe outsole additionally may include flocking 55 (See FIG. 4) provided on the surface of the ball region 38 by adhering or otherwise affixing the flocking material to the surface of the ball region 38 to provide increased cushioning, and traction or friction. It should also be appreciated that the shoe outsole 10 could be manufactured without placing flocking in the ball region 38 since the tread pattern formed in the ball region will provide adequate cushioning and traction for the wearer.

The shoe outsole bottom surface preferably includes a second region or heel region 56 of the shoe outsole in an area of a heel of a user's or wearer's foot. The second region or heel region 56 preferably has a contiguous shape with a fourth lobe 58 and a fifth lobe 60 that are connected together to form a right angle shape or J-shaped region conforming to an outside area of a heel of the wearer. The second region or heel region 56 is preferably delineated by a second channel 62. The fourth lobe 58 preferably extends substantially longitudinally along the outside area 64 of the heel, corresponding to and provided for supporting and cushioning of the heel of the user or wearer, and the fifth lobe 60 preferably extends substantially perpendicular to the fourth lobe, substantially along a rear area of the heel, for supporting and cushioning of the heel of the user, as well as providing improved traction.

The heel region 56 of the shoe outsole preferably has a bottom surface including the first raised portion or ridges 66 and first recessed portions or grooves 68 extending laterally perpendicular to the longitudinal axis, and additionally preferably includes second raised portions or ridges 70 extending longitudinally to provide a surface for adhering flocking to the heel region 56 of the shoe outsole. Spaces 72 are formed between adjacent second ridges 70. These second raised portions or ridges 70 preferably extend outwardly beyond the first raised portions or ridges 66 in the heel region 56. Additionally, second raised ridges 70 could be placed on the surface of the recessed grooves 68 formed in the heel region 56 (not shown in the drawings) in order to improve adhesion of flocking to the shoe outer sole. In FIG. 2, these second raised ridges 70 are shown placed on only one of the first raised ridges 66 located in the heel region 56 for illustrative purposes. However, it again should be appreciated that second raised ridges 70 could be placed on additional or all of the first raised ridges 66 located in the heel region 56. The height of the first raised portions or ridges 66 in the heel region 56 can be greater than the height of the first raised portions or ridges 30 located in the main common region 28 to provide additional cushioning to the wearer's foot in the heel area. Additionally, the longer height of the first raised ridges 66 in the heel region 56 creates a longer projection which can be used to secure the flocking (described below) to the show outsole 10. Generally, the height of the first raised ridges 66 in the heel region 56 is about 0.5 to 2.0 millimeters greater that the height of the first raised ridges 30 located in the main common bottom region 28.

In a presently preferred embodiment, the shoe outsole additionally includes flocking 74, shown in FIG. 4, provided on the surface of the heel region 56 by adhering or otherwise affixing the flocking material to the surface of the heel region to provide increased cushioning, and traction or friction. It should also be appreciated that the shoe outsole 10 could be manufactured without placing flocking in the heel region 56 since the tread pattern formed in the ball region will provide adequate cushioning and traction for the wearer.

The channels, raised portions or ridges, and recessed portions or grooves, can be formed during molding of the outsole, or by cutting, etching or other similar suitable methods, for example. The flocking material can be, for example, Nylon fluff or any other suitable fluff material. Typically, the flocking material can be applied using adhesives using known techniques that may include high voltage electrostatic discharge. Any of the methods described above in the Background section could be used for applying the flocking to the ball and heel regions 38, 56 of the shoe outsole.

The height of the second raised ridges utilized in the above-described embodiment can be about 0.10 to 0.50 millimeters above the surface of the first raised ridge upon which the second raised ridge is placed. It should be further recognized that the particular shape of the first and second raised ridges shown in the disclosed embodiment can be changed without departing from the spirit and scope of the invention.

It will be apparent from the foregoing that, while particular forms of the invention have been illustrated and described, various modifications can be made without departing from the spirit and scope of the invention. Accordingly, it is not intended that the invention be limited, except as by the appended claims. 

1. A shoe outsole having a front toe, a rear heel, and medial and lateral side edges therebetween, a length with a longitudinal axis, a width, and a main bottom surface, comprising: a main common region including a tread pattern including first ridges and grooves extending laterally perpendicular to the longitudinal axis; a ball region of the shoe outsole in an area of a ball of a wearer's foot, said ball region having a contiguous “butterfly” shape with a first longitudinally extending lobe, a second longitudinally extending lobe, and a narrower third middle lobe connected therebetween, said ball region of the shoe outsole including a tread pattern including first ridges and grooves extending laterally perpendicular to the longitudinal axis; and a heel region of the shoe outsole in an area of a heel of the wearer's foot, said heel region having a contiguous shape with fourth and fifth lobes connected together and forming the heel region in a J-shape conforming to an outside area of a heel of the wearer, said fourth lobe extending generally longitudinally along the outside area of the heel of the wearer, and said fifth lobe extending generally perpendicular to the fourth lobe generally along a rear area of the wearer's heel, said heel region including a surface having said tread pattern including first ridges and grooves extending laterally perpendicular to the longitudinal axis.
 2. The shoe outsole of claim 1, wherein the first ridges located in the main common region have a particular height and the first ridges in the ball region have a particular height, the height of the first ridges in the ball region being greater that the height of the first ridges in the main common region.
 3. The shoe outsole of claim 1, wherein the first ridges located in the main common region have a particular height and the first ridges in the heel region have a particular height, the height of the first ridges in the heel region being greater that the height of the first ridges in the main common region.
 4. The shoe outsole of claim 1, wherein said first ridges of the ball region and heel region additionally include second ridges and grooves which project from the surface of the ridges and extend longitudinally with the longitudinal axis.
 5. The shoe outsole of claim 1, wherein said first longitudinally extending lobe is disposed on a medial side of said ball region of the shoe outsole.
 6. The shoe outsole of claim 5, wherein said first longitudinally extending lobe is longer than the second longitudinally extending lobe.
 7. The shoe outsole of claim 1, wherein said second longitudinally extending region is disposed on a lateral side of said ball region of the shoe outsole.
 8. The shoe outsole of claim 1, wherein said second ridges extend outwardly beyond said first ridges and grooves.
 9. The shoe outsole of claim 1, further comprising flocking material adhered to the bottom surface of said ball region.
 10. The shoe outsole of claim 1, further comprising flocking material adhered to the bottom surface of said heel region.
 11. A shoe outsole having a front toe, a rear heel, and medial and lateral side edges therebetween, a length with a longitudinal axis, a width, and a main bottom surface, comprising: a main common region including a tread pattern including first ridges and grooves extending laterally perpendicular to the longitudinal axis; a ball region of the shoe outsole in an area of a ball of a wearer's foot, said ball region having a contiguous “butterfly” shape formed by a channel which extends into the main common region, the contiguous “butterfly” shape including a first longitudinally extending lobe, a second longitudinally extending lobe, and a narrower third middle lobe connected therebetween, said ball region of the shoe outsole including a tread pattern including first ridges and grooves extending laterally perpendicular to the longitudinal axis; and a heel region of the shoe outsole in an area of a heel of the wearer's foot, said heel region having a contiguous shape formed by a channel which extends into the main common region, the contiguous shape including fourth and fifth lobes connected together and forming the heel region in a J-shape conforming to an outside area of a heel of the wearer, said fourth lobe extending generally longitudinally along the outside area of the heel of the wearer, and said fifth lobe extending generally perpendicular to the fourth lobe generally along a rear area of the wearer's heel, said heel region including a surface having said tread pattern including first ridges and grooves extending laterally perpendicular to the longitudinal axis.
 12. The shoe outsole of claim 11, wherein the channels forming the shapes of the ball region and heel region are cut into the first ridges of the main common region.
 13. The shoe outsole of claim 11, wherein the first ridges located in the main common region have a particular height and the first ridges in the ball region have a particular height, the height of the first ridges in the ball region being greater that the height of the first ridges in the main common region.
 14. The shoe outsole of claim 11, wherein the first ridges located in the main common region have a particular height and the first ridges in the heel region have a particular height, the height of the first ridges in the heel region being greater that the height of the first ridges in the main common region.
 15. The shoe outsole of claim 14, wherein the first ridges located in the main common region have a particular height and the first ridges in the heel region have a particular height, the height of the first ridges in the heel region being greater that the height of the first ridges in the main common region.
 16. The shoe outsole of claim 11, wherein said first ridges of the ball region and heel region additionally include second ridges and grooves which project from the surface of the ridges and extend longitudinally with the longitudinal axis. 